Optical thin film with high hardness made by insert mold technology and manufacturing  processes thereof

ABSTRACT

An optical thin film with high hardness made by insert mold technology and manufacturing processes thereof are disclosed. The optical thin film is applied on surface of a plastic housing for increasing hardness of the plastic housing so as to prevent scratches. During manufacturing processes of insert mold for producing a hard coating film, the step of hardening treatment is moved to the last step so as to avoid cracks on the optical thin film generated during the procedures. Thus the yield rate is increased and the manufacturing cost is reduced.

BACKGROUND OF THE INVENTION

The present invention relates to a plastic film, especially to an optical thin film made by insert mold technology and manufacturing processes thereof.

Due to prevalence of mobile phones and notebooks, users have higher demands of housings of them. Besides requirements of styles and colors, hardened surface for preventing scratches is also important. The hardening treatment for preventing scratches is applied on electronics such as notebooks, mobile phones, and personal digital assistants (PDA) with colorful and smooth plastic surface made by injection molding. Besides, it can also be applied to wood panels and wheel rims.

Refer to FIG. 1, a conventional way for surface coating of a film on plastic housings is disclosed. Refer to step S100′, prepare a plastic material made from polycarbonate (PC), polypropylene (PP), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), acrylonitrile butadine styrene (ABS), polystyene (PS), polyethylene terephthalate (PET), polyacetal, polyoxy Methylene (POM) or Nylon. Then take step S110′, forming shape of a housing by injection molding. Run step S120′, painting various figures or colors on surface of the housing by spray coating; during the processes of spray coating, masking paint is used repeatedly to form the figures or words. Refer to step S130′, spray coat transparent curable coating such as extenders or lacquer. Next take step S140′, spray coat the anti-scratch coating. Finally, run step S150′, use ultraviolet curing treatment to harden the anti-scratch coating.

The method mentioned above paints various figures or colors on surface of housings by spray coating. It takes long time to use masking paints or attach adhesive tapes repeatedly. The processes are not only complicated but also generated pollutions and waste of paints caused by a lot of spray. Moreover, most of conventional paints contain lead or other heavy metal so that they violate regulations of Restriction of Hazardous Substance (ROHS). And the layer of transparent curable coating causes waste of coating, unevenly distribution, and surface roughening. Furthermore, there may be piling due to turnings or curves on surface. And this lead to fogging problem while the optical thin film is treated by heat or ultraviolet light, or the size is not right after being assembled.

Refer to FIG. 2, manufacturing processes of an insert mold decoration technology for printing, forming, and molding of a decorated film are disclosed. Refer to step S200′, provide a transparent optical thin film already being harden treated. Take the step S210′, print preformed figures or colored layer under the optical thin film by direct printing or transfer printing. Refer to step S220′, make the optical thin film form the required shape by hot stamping or thermal vacuum forming. The run the step S230′, a plastic material is injected under the figures by injection molding to form a final product.

Refer to FIG. 2A, an optical thin film made by insert mold decoration (IMD) is disclosed. The optical thin film includes a figured layer under the optical thin film layer and a plastic material disposed under the figured layer.

However, the insert mold decoration technology firstly takes the hardening treatment of the optic film and then runs the injection molding procedure. Due to increased hardness, during the following procedures such as heat treatment and injection molding, the optical thin film is easy to have cracks or wrinkles on turnings or corners up. Also it may have fogging.

SUMMARY OF THE INVENTION

Therefore it is a primary object of the present invention to provide an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof. During the steps of hot stamping or thermal vacuum forming, there are no problems of cracks, wrinkles, or fogging because the hardness of the optical thin film has not been increased. Thus the yield rate of products is increased. Moreover, the optical thin film has a hardened layer that is treated by UV light after the products being formed so that the hardness of the optical thin film is increased.

It is another object of the present invention to provide an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof. The preformed figures or colors are printed under the optical thin film by direct printing or transfer printing. Then the optical thin film is formed into required shape by hot stamping or thermal vacuum forming and a plastic substrate is injected under the optical thin film so that the required figures or colors are printed on the housing. Compared with traditional spray coating that uses shielding paints or adhesive tapes repeatedly, the present invention saves coatings.

It is another object of the present invention to provide an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof that runs surface coating inside the mold before the product releasing from the mold. Thus the steps of injection molding, surface coating and polishing are integrated into one step so as to save energy, simplify processing procedures, and reduce manufacturing cost.

In conventional IMD technology, an optical thin film is hardened in the beginning. Thus during hot stamping or thermal vacuum processes for shaping the optical thin film, the optical thin film may generate cracks, wrinkles, or fogging due to the hardened layer so that the yield rate is reduced.

Moreover, after the housing being injection molded, figures or colors are coated on surface thereof by spray coating. The processes of paint masking applications or tapes attachment are time-consuming and complicated. Furthermore, one more layer of hardened coating is applied. This may raise problems of coating waste, unevenly distribution, and surface roughening. And the piling is happened due to turnings or curves on surface. This lead to fogging problem while the optical thin film is treated by heat or ultraviolet light, or the size is not right after being assembled.

Therefore, the present invention provides an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof. A hardened layer is formed above the optical thin film that is not hardened. Then a figurative or colored layer is printed under the optical thin film. Later a plastic material is injected under the figurative or colored layer by injection molding. At last, the hardened layer is treated by UV light. Thus there are no problems of cracks, wrinkles and fogging during hot stamping or thermal vacuum process. As a result, the yield rate is improved. Moreover, the figurative or colored layer is formed under the optical thin film by direct printing or transfer printing. There is no waste of paints. Furthermore, surface coating is done directly inside the mold before the product releasing from the mold. Thus the steps of injection molding, surface coating and polishing are integrated into one step so that the energy is saved, processing procedures are simplified, and the manufacturing cost is reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein

FIG. 1 is a flow chart of conventional technology for coating film on plastic housings;

FIG. 2 is a flow chart showing manufacturing processes of conventional insert mold decoration technology;

FIG. 2A is a schematic drawing showing structure of an optical thin film made by conventional insert mold decoration technology;

FIG. 3 is a flow chart of showing manufacturing processes of another embodiment according to the present invention with high hardness made by insert mold decoration technology;

FIG. 3A is a schematic drawing showing the hardened layer formed above the optical thin film;

FIG. 3B is a schematic drawing showing a protective film formed above the hardened layer;

FIG. 3C is a schematic drawing showing a figure formed under the optical thin film;

FIG. 3D is a schematic drawing showing the protective film being taken off;

FIG. 3E is a schematic drawing showing the shaping of the optical thin film through heat treatment; and

FIG. 3F is a schematic drawing showing the plastic material injected under a figure by injection molding.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

During a conventional IMD technology, while taking the steps of hot stamping or thermal vacuum forming, the optical thin film has been through hardening treatment so there may be problems of cracks, wrinkles or fogging. Thus the present invention provides an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof for improving above disadvantages.

Refer from FIG. 3 to FIG. 3D, in step S200, prepare an optical thin film 1 that has not been through hardening treatment. The material of the optical thin film 1 is selected from one of the followings: polyethylene terephthalate (PET), polycarbonate (PC), Triacetyl Cellulose (TAC), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), and cyclic olefins copolymer (COC). In this embodiment, take film made from polycarbonate as an example, the thickness of the film is 250 μm while the grade of hardness is 2 B.

Refer to step S210, a hardened layer is formed above an optical thin film. As shown in FIG. 3A, a hardened layer 2 with a thickness of 15 μm is formed above the optical thin film 1 by roll coating. The hardened layer 2 is formed by coating of UV curing resin that is selected from high molecular weight acrylate oligomer with a plurality of functional groups, polyurethane acrylate oligomer, monomer or combinations of them.

In step S220, heat the hardened layer to unstuck status. Heat the hardened layer at 110 Celsius degrees for 5 minutes to make the residual solvent volatilize for quick drying and becoming into unstuck status. The manufacturing time is shortened.

Refer to step S230, provide a protective film attached above the hardened layer. As shown in FIG. 3B, a protective film 5 is attached above the hardened layer 2 so as to prevent contamination of the hardened layer 2.

In step S240, a figure is formed under the optical thin film. Refer to FIG. 3C, the FIG. 3 is directly printed under the optical thin film 1. The figure can be a colored layer or other forms with aesthetics appearance. Besides direct printing, the way of transfer printing can be used.

In step S250, the protective film is taken off. Refer to FIG. 3D, the protective film over the hardened layer 2 is taken off.

In step S260, the optical thin film is preformed through heat treatment. Refer to FIG. 3E, the optical thin film 1 is shaped into a housing 6 of mobile phones by thermal vacuum forming and then is moved into a mold.

In step S270, a plastic material is injected under the figure. As shown in FIG. 3F, a plastic material 4 is selected from polycarbonate (PC), polypropylene (PP), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), acrylonitrile butadine styrene (ABS), polystyene (PS), polyethylene terephthalate (PET), polyacetal, polyoxy Methylene (POM) or Nylon. In this embodiment, Acrylonitrile Butadine Styrene (ABS) is placed into an injection mold and the plastic material 4 is attached under the printed figure by injection molding. Thus the housing 6 of mobile phones is generated by injection molding and meanwhile the optical thin film 1 is attached thereof.

In step S280, the hardened layer is hardened by UV light. After the housing 6 of the mobile phone is formed by injection molding and is attached on the optical thin film 1, the hardened layer 2 is processed by UV energy output 2500 mJ/cm² so as to increase the hardness of the housing 6 of the mobile phone to grade H.

In this embodiment, the processes of heating, printing the figures and attaching the protective film are added so as to shorten the drying time, improve the appearance and avoid contamination of the hardened layer while printing figures or colors.

In accordance with the present invention, there are various ways of coating to form the hardening layer. For example, slot coating in which a coating liquid is pumped through a slot die at a constant rate against a web and then fills the space between the lips of the die and the web when the web moves under the die. After the web moves out the die, the fluid doesn't contact with the web so that the coating is finished. Curtain coating is applying liquid to an object by passing the object under a thin curtain of liquid falling by gravity or pressure. The roll coating is applied by a roller and smoothed by the reverse action of the preceding roller. One of above ways is selected for coating the hardened layer on the optical thin film

In summary, the present invention provides an optical thin film with high hardness made by insert mold technology and manufacturing processes thereof that avoids cracks, wrinkles and fogging of the optical thin film during procedures of hot stamping or thermal vacuum forming by changing the step of hardening treatment. And the yield rate is increased. Moreover, the figure is formed on the housing by direct printing or transfer printing so as to save coatings. And the unevenly distribution as well as surface roughening is prevented. There is no piling on turnings or curves of surface and no fogging after hardening treatment. At last, the surface coating is done inside the mold before the product releasing from the mold so that the steps of injection molding, surface coating and polishing are integrated into one step for saving energy, simplifying processing procedures, and reducing manufacturing cost.

Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. 

1. A manufacturing processes for an optical thin film with high hardness made by insert mold technology comprising the steps of: providing an optical thin film not being hardened yet; forming a hardened layer above the optical thin film; preforming the optical thin film through heat treatment; forming a plastic material under the optical thin film by injection molding; and hardening the hardened layer by ultraviolet(UV) light.
 2. The manufacturing processes for the optical thin film as claimed in claim 1, wherein after the step of forming a hardened layer above the optical thin film, the processes further comprising a step of: forming a figure under the optical thin film.
 3. The manufacturing processes for the optical thin film as claimed in claim 2, wherein on the step of forming a figure under the optical thin film, the figure can be a color layer.
 4. The manufacturing processes for the optical thin film as claimed in claim 2, wherein a way to forming a figure is direct printing or transfer printing.
 5. The manufacturing processes for the optical thin film as claimed in claim 2, wherein before the step of forming a figure under the optical thin film, the processes further comprising a step of: providing a protective film attached above the hardened layer.
 6. The manufacturing processes for the optical thin film as claimed in claim 5, wherein after the step of forming a figure under the optical thin film, the processes further comprising a step of: taking off the protective film.
 7. The manufacturing processes for the optical thin film as claimed in claim 1, wherein after the step of forming a hardened layer above the optical thin film, the processes further comprising a step of: heating the hardened layer to unstuck status.
 8. The manufacturing processes for the optical thin film as claimed in claim 7, wherein temperature of heating ranges from 70 Celsius degrees to 200 Celsius degrees.
 9. The manufacturing processes for the optical thin film as claimed in claim 7, wherein temperature of heating is preferably from 100 Celsius degrees to 280 Celsius degrees.
 10. The manufacturing processes for the optical thin film as claimed in claim 7, wherein time of heating ranges from 3 minutes to 120 minutes.
 11. The manufacturing processes for the optical thin film as claimed in claim 9, wherein time of heating is preferably from 5 minutes to 90 minutes.
 12. The manufacturing processes for the optical thin film as claimed in claim 1, wherein the way of forming the hardened layer is slot coating, roll coating or curtain coating.
 13. The manufacturing processes for the optical thin film as claimed in claim 1, wherein the UV energy output ranges from 300 mJ/cm² to 3000 mJ/cm².
 14. The manufacturing processes for the optical thin film as claimed in claim 1, wherein way of heat treatment includes hot stamping or thermal vacuum.
 15. An optical thin film with high hardness made by insert mold technology comprising: an optical thin film; a hardened layer disposed above the optical thin film; and a plastic material disposed under the optical thin film wherein the hardened layer and the plastic material are respectively disposed above and under the optical thin film by insert mold technology.
 16. The optical thin film as claimed in claim 15, wherein a figured layer is disposed under the optical thin film.
 17. The optical thin film as claimed in claim 15, wherein a colored layer is disposed under the optical thin film.
 18. The optical thin film as claimed in claim 15, wherein the optical thin film is made from polyethylene terephthalate (PET), polycarbonate (PC), Triacetyl Cellulose (TAC), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), or cyclic olefins copolymer
 19. The optical thin film as claimed in claim 15, wherein the plastic material is selected from one of polycarbonate (PC), polypropylene (PP), polymeric methyl methacrylate (PMMA), methyl methacrylate styrene copolymer (MS), acrylonitrile butadine styrene (ABS), polystyene (PS), polyethylene terephthalate (PET), polyacetal, polyoxy Methylene (POM) and Nylon.
 20. The optical thin film as claimed in claim 15, wherein a thickness of the optical thin film ranges from 3 μm to 300 μm.
 21. The optical thin film as claimed in claim 15, wherein a thickness of the hardened layer ranges from 3 μm to 50 μm.
 22. The optical thin film as claimed in claim 15, wherein material of the hardened layer includes UV curing resin.
 23. The optical thin film as claimed in claim 22, wherein the UV curing resin is selected from high molecular weight acrylate oligomer with a plurality of functional groups, polyurethane acrylate oligomer, monomer or combinations of them. 